Reduce overpackaging
Description
Packaging can be minimized while maintaining functionality and user convenience by reducing overpackaging (3). Overpackaging includes unnecessary headspace, overly large packaging, and avoidable components, such as caps. In addition to cutting costs and waste, reducing overpackaging is popular with consumers as many people prefer smaller packages and get frustrated when plastic packaging seems unnecessarily wasteful.
At a glance
Key benefits:
- Developing custom-size packaging can reduce overpackaging: Ensure that the shape and size of packaging matches the product in question, and avoid excessive packaging material, void fill, or oversized packaging (3). Reducing overpackaging, such as by cutting unnecessary headspace, can lead to less packaging material as well as lower transport costs and savings in greenhouse gas emissions (2).
- Packaging reduction can be facilitated by novel packaging and design concepts: Consider switching the packaging type as some packaging concepts, such as vacuum skin packs or folded packs, can reduce the amount of material or packaging volume needed (3). For luxury items packaged in several layers/boxes, these attractive effects can be created using graphics, higher-quality print and packaging materials, or point-of-sale displays instead of extra packaging volume (4).
Key cautions:
- Make sure barrier properties and other packaging functions can still be met while reducing overpackaging: Overpackaging is defined as packaging that is unnecessary in terms of functionality. For some products, such as yogurt containers, a small headspace may fulfill essential functions for preservation. Effective packaging-reduction solutions are those that still fulfill essential functions, such as those related to product protection, machine requirements, or shipping and handling (2).
Where to start
- Minimize headspace in trays, containers, pouches, or plastic bags that are often packaged in larger packaging than needed, sometimes to increase the perceived product size. For instance, potato chip packets are often double the volume of the product. Minimizing headspace can be especially relevant for e-commerce in which shelf appeal plays little to no role.
- Minimize wrapping volume to the smallest amount needed to protect/hold together the product. This can be done by reducing the layers of wrapping, minimizing the packaging size, or changing the design of multi-wrappings using solutions like multi-pack handles.
- Minimize sealing packaging material by utilizing new sealing approaches that reduce the size of the liner back seal.
- Minimize the size/volume of attachments such as caps, or – ideally – combine them with the main packaging.
Current applicability per plastic type
Note: High in this instance implies the solution is highly applicable to the plastic type. Medium indicates potential to apply this solution to the relevant plastic type in some cases. Low implies major barriers and, generally speaking, this solution cannot be used in conjunction with the plastic type.
Solutions. and case studies
Many examples of successful reuse programs for plastic packaging are currently from outside the U.S. However, more U.S. case studies are emerging and will be included in the future. The following are used for general information and illustrative purposes and do not reflect a preference of or an endorsement by The Recycling Partnership or our affiliates or vendors.
- KHS Nature Multi Pack: KHS developed multi-pack tape handles that use 86% less packaging material than conventional multi-packs, provide increased pack strength for logistics, are easy to carry, and can convey marketing messages. (Link)
- Marks & Spencer salad packaging reduction: Marks & Spencer minimized packaging by reducing the size of the liner back seal of its salad bags by using a new heat-sealing approach with only a 1-mm wide weld (5). (Link)
- Wotsits crisps air minimization: While most potato chip packets contain more than 50% (and up to 72%) air, Wotsits were found to only include 18% air. (Link)
- Poland Spring water cap reduction: The caps on Poland Spring bottles contain the least amount of plastic compared to other caps. (Link)
Reports and References
(1) Ellen MacArthur Foundation: Upstream Innovation. A guide to packaging solutions. (Link)
(2) Consumer Goods Forum (2021). The Golden Design rules. (confidential document)
(3) Packaging Europe: Reduction of material usage – a different path to the same goal. (Link)
(4) Packaging Fed. (Link)
(5) WRAP (2009). Efficient use of resources in breakfast cereal design packaging. (Link)
